U.S. patent number 8,789,748 [Application Number 13/608,247] was granted by the patent office on 2014-07-29 for method and apparatus for handling packages.
This patent grant is currently assigned to MedAvail, Inc.. The grantee listed for this patent is Richard Panetta, Leigh Pauls, Peter Suma, Donald Waugh. Invention is credited to Richard Panetta, Leigh Pauls, Peter Suma, Donald Waugh.
United States Patent |
8,789,748 |
Waugh , et al. |
July 29, 2014 |
Method and apparatus for handling packages
Abstract
A vending machine. In a method and apparatus for handling a
package in an automated dispensary, a package is positioned in an
inspection station of the dispensary. Images are captured of the
package and are read to identify data on labels or on the package
itself. The data is encoded as source data in an identifying label
which is applied to the package and is used subsequently in
handling the package for dispensing and other inventory management
procedures.
Inventors: |
Waugh; Donald (Oakville,
CA), Panetta; Richard (Milton, CA), Suma;
Peter (Aurora, CA), Pauls; Leigh (St. Catherines,
CA) |
Applicant: |
Name |
City |
State |
Country |
Type |
Waugh; Donald
Panetta; Richard
Suma; Peter
Pauls; Leigh |
Oakville
Milton
Aurora
St. Catherines |
N/A
N/A
N/A
N/A |
CA
CA
CA
CA |
|
|
Assignee: |
MedAvail, Inc. (San Francisco,
CA)
|
Family
ID: |
44352894 |
Appl.
No.: |
13/608,247 |
Filed: |
September 10, 2012 |
Prior Publication Data
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Document
Identifier |
Publication Date |
|
US 20130251479 A1 |
Sep 26, 2013 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
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12701372 |
Sep 18, 2012 |
8267310 |
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Current U.S.
Class: |
235/375;
235/487 |
Current CPC
Class: |
G06K
9/2036 (20130101); G07F 11/165 (20130101); G16H
20/13 (20180101); B65G 47/74 (20130101); G06K
2209/19 (20130101) |
Current International
Class: |
G06F
17/00 (20060101) |
Field of
Search: |
;235/375,487,385,462.01 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Labaze; Edwyn
Attorney, Agent or Firm: DeSandro; Bradley K. Desandro Law
Group PLLC
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATIONS
This is a continuation of application of U.S. patent application
Ser. No. 12/701,372, filed on Feb. 5, 2010, titled "Method and
Apparatus for Handling Packages in an Automated Dispensary," now
U.S. Pat. No. 8,267,310, which is incorporated herein by reference.
Claims
What is claimed is:
1. For a plurality of packages in respective storage stations
within an apparatus, each having a substantially planar outside
surface bearing a symbol thereon, a method for each said package
comprising: retrieving the package from the corresponding said
storage station; moving the package to an inspection station inside
the apparatus; rotating the package about an axis of the
substantially planar outside surface such that it is generally
perpendicular to: an illumination of light emitted by a light
source in the inspection station; and a viewing axis of one of an
image capture camera in the inspection station; capturing an image
of the symbol borne on the substantially planar outside surface of
the package that is generally perpendicular to: the illumination of
light emitted by the light source in the inspection station; and
the viewing axis of the image capture camera in the inspection
station; reading the symbol in the captured image to identify
source data; encoding the source data to obtain first encoded data;
applying an identifying label bearing the first encoded data to the
package; retrieving the labeled package from the inspection station
inside the apparatus; and moving the labeled package to one of the
storage stations inside the apparatus.
2. The method as defined in claim 1, wherein the retrieving of one
said labeled package from one said storage station inside the
apparatus further comprises using the index of the serialization
codes against the storage stations for the retrieving of one said
labeled package from one said storage station inside the
apparatus.
3. The method as defined in claim 2, wherein the symbol in the
captured image of the substantially planar outside surface of the
package includes character data, and the method further comprises
reading the character data with an optical character recognition
reader.
4. The method as defined in claim 1, wherein: the apparatus is a
node on a communications network; and the reading of the symbol in
the captured image further comprises transmitting the captured
image from the dispensary in a transmission addressed for delivery
to a remote node on the network whereby the symbol in the captured
image can be manually read at the remote node to derive a manually
viewed part of the source data.
5. The method as defined in claim 1, wherein the identifying label
includes an identifier selected from the group consisting of a
pictogram, a printed code, a bar code, a radio frequency
identifier, and a combination thereof.
6. The method as defined in claim 1, further comprising: receiving
a written request from a user of the apparatus; optically scanning
the written request to receive an optical image of the written
request; retrieving one said labeled package from one said storage
station inside the apparatus, wherein information in the optical
image of the written request corresponds to the first encoded data
on the identifying label on the retrieved one said labeled package;
and dispensing the retrieved one said labeled package to the user
of the apparatus.
7. The method as defined in claim 1, further comprising: receiving
a request from a user of the apparatus; and retrieving one said
labeled package having the first encoded data on the identifying
label corresponding to the request from the user.
8. The method as defined in claim 1, further comprising, for each
said package in the inspection station: measuring a physical
property of the package to derive physical data; encoding the
physical data to obtain second encoded data; and applying the
second encoded data to the identifying label.
9. The method as defined in claim 1, wherein: the illumination of
light emitted by the light source in the inspection station is an
illuminating sub-system; the capturing of the image of the symbol
is a recording sub-system; and the method further comprises:
recording a provisional image of the package with the illuminating
subsystem; and prior to capturing of the image of the symbol borne
on the substantially planar outside surface of the package:
analyzing the provisional image quality; and adjusting at least one
of the illuminating sub-system and the recording sub-system to
increase a quality of the provisional image.
10. The method as defined in claim 1, wherein: the first encoded
data is a serialization code; and the method further comprises
storing an index of said serialization codes against corresponding
source data.
11. The method as defined in claim 10, further comprising storing
the index of the serialization codes against the storage
stations.
12. An apparatus having therein a plurality of packages in
respective storage stations, each having a substantially planar
outside surface bearing a symbol thereon, the apparatus comprising:
a first mover module operable, for each said package, to: retrieve
the package from the corresponding said storage station; and move
the package to an inspection station inside the apparatus; an
inspection module in the inspection station operable, for each said
package, to rotate the package about the axis of the substantially
planar outside surface such that it is generally perpendicular to:
an illumination of light emitted by a light source in the
inspection station; and a viewing axis of an image capture camera
in the inspection station; an image capture module operable to
capture an image of the substantially planar outside surface of the
package that is generally perpendicular to: the illumination of
light emitted by the light source in the inspection station; and
the viewing axis of one of the image capture camera in the
inspection station; a reading module operable to read the symbol in
the captured image to identify source data; an encoding module
operable to encode the source data to obtain first encoded data; a
labeling module operable to apply the first encoded data as an
identifying label to the retrieved package; a first retrieving
module operable to retrieve the labeled package from the inspection
station; and a second mover module operable to move the labeled
package to one of the storage stations.
13. The apparatus as defined in claim 12, further comprising: a
user request receiver module operable to receive a written request
from a user of the apparatus; a scanning module operable to
optically scanning the written request to receive an optical image
of the written request; a matching module operable to match
information in the optical image of the written request
corresponding to the first encoded data on the identifying label on
one said; a second retrieving module operable to retrieve the
matching said labeled package from one said storage station inside
the apparatus; and a dispensing module operable to dispensing the
retrieved matching said labeled package to the user of the
apparatus.
14. The apparatus as defined in claim 12, wherein the reading
module is at least one of a printed character reader and an
embossed character reader.
15. The apparatus as defined in claim 12, wherein: the apparatus is
a node on a communications network; and the reading module is
further operable to transmit each said captured image from the
dispensary in a transmission addressed for delivery to a remote
node on the network whereby the captured image can be manually read
at the remote node to derive a manually viewed part of the source
data.
16. The apparatus as defined in claim 12, wherein the identifying
label applied to the retrieved package includes an identifier
selected from the group consisting of a pictogram, a printed code,
a bar code, a radio frequency identifier, and a combination
thereof.
17. The apparatus as defined in claim 12, wherein: the illumination
module further comprises multiple light sources to illuminate the
package from a plurality of directions; and the image capture
module has image capture sub-units to capture images of the package
as viewed from a corresponding plurality of directions.
18. The apparatus as defined in claim 12, further comprising a
physical property measuring module to measure at least one physical
property of the package to derive physical data, wherein: the
encoding module is operable to encode the physical data to obtain
second encoded data; and the labeling module is operable to label
the package with a label embodying the second encoded data.
19. The apparatus as defined in claim 12, wherein: the illumination
of light emitted by the light source in the inspection station is
an illumination module; the image capture module is further
operable to capture a provisional image of the package: the reading
module is further operable to: read the provisional image; and
develop a feedback signal; and the apparatus further comprises a
feedback loop to apply the feedback signal to adjust settings of at
least one of: a corresponding said illumination module; and the
image capture module.
20. For an apparatus that is a node on a communications network and
stores a plurality of packages in respective storage stations
inside the apparatus, each said package having a substantially
planar outside surface bearing a symbol thereon, a method, for each
package, comprising: retrieving the package from the corresponding
said storage station; moving the package to an inspection station
inside the apparatus; rotating the package about one or more axes
of the substantially planar outside surface such that it is
generally perpendicular to: an illumination of light emitted by a
light source in the inspection station, wherein the illumination of
light emitted by the light source in the inspection station is an
illuminating sub-system; and a viewing axis of an image capture
camera in the inspection station that is a recording sub-system;
recording a provisional image of the package with the recording
sub-system; analyzing a quality of the provisional image; adjusting
at least one of the illuminating sub-system and the recording
sub-system to increase the quality of the provisional image;
capturing, after said recording, analyzing and adjusting, an image
of the symbol borne on the substantially planar outside surface of
the package that is generally perpendicular to: the illumination of
light emitted by the light source in the inspection station; and
the viewing axis of the image capture camera in the inspection
station; reading the captured image to identify source data;
transmitting the captured image from the apparatus in a
transmission addressed for delivery to a remote node on the
network, whereby the captured image can be manually read at the
remote node to derive a manually viewed part of the source data;
encoding the source data to obtain first encoded data; measuring a
physical property of the retrieved package to derive physical data;
encoding the physical data to obtain second encoded data; applying
the first and second encoded data as an identifying label to the
package; retrieving the labeled package from the inspection station
inside the apparatus; moving the labeled package to one of the
storage stations inside the apparatus; receiving a written request
from a user of the apparatus; optically scanning the written
request to receive an optical image of the written request;
retrieving one said labeled package from one said storage station
inside the apparatus, wherein information in the optical image of
the written request corresponds to the first encoded data on the
identifying label on the retrieved one said labeled package; and
dispensing the retrieved one said labeled package to the user of
the apparatus.
Description
FIELD
This invention relates to a method and apparatus for handling
packages in an automated dispensary. The invention has particular
but not exclusive application to serializing medicament packages in
preparation for dispensing from an automated medicament
dispensary.
BACKGROUND
The traditional means of dispensing prescribed medicaments involves
a doctor meeting with a patient and prescribing a medicament based
on a particular diagnosis, and then hand writing and signing a
prescription for the patient to carry to a pharmacist at a pharmacy
location for fulfillment. In recent years, two significant advances
have occurred in the field of medicament dispensing. The first is
the advent of electronic prescription capturing methods, systems
and apparatus, which improve the overall accuracy and patient
record-keeping associated with prescribing medicaments. The second
is the advent of automated apparatus, typically configured as
dispensaries, from which medicaments can be automatically
dispensed, the dispensaries being located for convenient patient
access, such as at a doctor's premises, a hospital or mall. In the
use of automated dispensaries, the dispensaries are stocked,
medicaments are periodically dispensed to patients, and the
dispensaries are restocked. For patient safety, it is necessary to
verify that valid medicaments are being dispensed to patients. An
important step in such verification is serializing all products
that are stocked at the dispensary. Serialization is valuable also
for effective inventory management. However, serializing products
can be time consuming and inconvenient if all products that are to
be stocked in a large number of distributed kiosks have to be
brought to a central depot for serializing. There is also the risk
of loss or damage of products in transporting them to and from the
serializing depot. Similarly, to have a person operate dedicated
serializing equipment which is either installed at a kiosk or is
taken there by a service person can be time consuming and
costly.
SUMMARY
According to one aspect of the invention, there is provided a
method of handling a package in an automated dispensary, the method
comprising positioning the package in an inspection station of the
dispensary, capturing an image of the package, reading the image to
identify source data, encoding the source data to obtain first
encoded data, and labeling the package with an identifying label
containing the first encoded data and serializing data. The label
can be any suitable label such as a bar code label or a radio
frequency identification label.
Preferably the reading of the image further comprises machine
reading at least a first part of the image at the inspection
station to derive a machine readable part of the source data. The
machine reading can further comprise optical character reading
printed characters of the image with an OCR reader and/or reading
embossed characters of the image with an embossed character reader.
Preferably, the dispensary is one node on a communications network,
the method further comprising transmitting the image from the
dispensary to a remote node, and, at the remote node, manually
reading the image to derive a manually viewed part of the source
data.
The method can further comprise illuminating the package from
several directions and capturing the respective image parts
corresponding to the package being viewed from several directions.
Optionally, with the package positioned in the inspection station,
a physical property of the package is measured to derive physical
data, the physical data is encoded to obtain second encoded data,
the second encoded data is combined with the first encoded data,
and the package is labeled with the identifying label containing
the combined data. The method can further comprise illuminating the
package with an illuminating module, recording a provisional image
of the package with an image capture module prior to capturing a
final image of the package by the image capture module, analyzing
the provisional image quality, and adjusting settings of at least
one of the illuminating module and the image capture module to
increase the provisional image quality and obtain the final
image.
According to another aspect of the invention, there is provided
apparatus for handling a package in an automated dispensary, the
apparatus comprising, at an inspection station of the dispensary,
an illumination module to illuminate the package, an image capture
module for capturing an image of the package, a character
identifying module to identify characterizing data from the image,
an encoding module to encode the characterizing data, and a
labeling module to apply a machine readable label bearing the
encoded characterizing data to the package.
Preferably the character identifying module has a reader for
reading machine readable characters in the image to derive a
machine readable part of the characterizing data, the reader being
at least one of a printed character reader and an embossed
character reader.
The dispensary can be a node on a communications network, the
character identifying module further including a link of the
communications network for transmission of the image from the
dispensary to a remote node of the communications network, and a
manual image inspection unit at the remote node to enable manual
inspection of a transmitted image.
The labeling module is preferably operable to apply one of a bar
code label and a radio frequency identification label to the
package. The illumination module can have multiple light sources to
illuminate the package from a plurality of directions, and the
image capture module can have multiple image capture camera units
to capture images of the package as viewed from a corresponding
plurality of directions.
The apparatus can further comprise a physical property measuring
module to measure at least one physical property of the package to
derive physical data, the encoding module operable to encode the
physical data to obtain second encoded data, and the labeling
module operable to label the package with a label embodying the
second encoded data. The image capture module is preferably
operable to capture a provisional image of the package, the reader
operable to read the provisional image and to develop a feedback
signal, and the apparatus further including a feedback loop to
apply the feedback signal to adjust settings of at least one of the
illumination module and the image capture module.
BRIEF DESCRIPTION OF THE DRAWINGS
For simplicity and clarity of illustration, elements illustrated in
the following figures are not drawn to common scale. For example,
the dimensions of some of the elements are exaggerated relative to
other elements for clarity. Advantages, features and
characteristics of the present invention, as well as methods,
operation and functions of related elements of structure, and the
combinations of parts and economies of manufacture, will become
apparent upon consideration of the following description and claims
with reference to the accompanying drawings, all of which form a
part of the specification, wherein like reference numerals
designate corresponding parts in the various figures, and
wherein:
FIG. 1 is front view of a vault of an automated dispensary showing
an inspection station;
FIG. 2 is a perspective view of a pick head mechanism for use in an
embodiment of the invention;
FIG. 3 is a circuit schematic diagram showing circuit modules used
in handling a package for an automated dispensary according to an
embodiment of the invention;
FIG. 4 shows a front view of an inspection station for an automated
dispensary according to an embodiment of the invention;
FIG. 5 shows a perspective view of part of another form of
inspection station according to an embodiment of the invention;
FIG. 6 is a plan view of part of the inspection station of FIG. 5;
and
FIG. 7 is a side view of another part of the inspection station of
FIG. 5.
DETAILED DESCRIPTION
In this specification, the term "medicament" encompasses drugs and
any and all other materials dispensed subject to presentation of a
prescription or script. The term "station" encompasses bins such as
storage and loading bins and other locations within an automated
dispensary to which a medicament package is taken and where a
package processing activity such as inspection takes place or
pending movement of the package to another location. The use of the
term "module" in the specification is to distinguish functionally
distinct parts of the package handling apparatus, which parts may
however comprise mechanical elements, control logic, processing
means and memory which are common to or shared by other parts.
Applicant's co-pending PCT Application Serial No. PCT/CA2007/001220
relates to a method, system and apparatus for dispensing
medicaments. More specifically, the PCT application describes a
networked system having a server, a database of patient information
linked to the server, a first client having input means linked to
the server and operable to generate a script for a medicament
prescribed to a user, a second client comprising an automated
dispensary at which medicaments can be dispensed to a user, the
dispensary including an input means operable to recognize a human
and/or machine readable description in the script, and to provide
validating cross-referencing between the description and patient
information as a prelude to dispensing a medicament to the user on
the basis of the input script. A doctor in a clinic can be a third
client having input means linked to the server to input appropriate
prescription information, or accept certain prescription
information from the database as being applicable in the particular
case for a particular patient. Further, the doctor's client device
can be operable to display patient information, e.g., medicament
history, insurance coverage, etc., and a printer module can print
the script as a paper print-out.
The server and database enable storing, compiling and retrieval of
patient data including name, address, and diagnostic and medicament
history. Access to the database can be provided to both the doctor
and the automated apparatus for dispensing medicaments via the
server, via a secure connection, or via a link between the system
and a clinic's existing clinic management system or patient
database.
The described apparatus may also includes a user interface, a
teleconferencing or video-conferencing means enabling communication
between the user and a human validation agent, and a scanning means
for capturing an image of the script so that it, if needed, it can
be viewed by a human validation agent, such as a licensed
pharmacist communicating in the system and with the apparatus from
a remote location to the apparatus, to approve a prescription. The
user interface of the dispensary apparatus provides detailed and
clear instructions to guide the user.
An authentication means confirms the identity of the patient, for
example, by prompting for a personal identification number or by
biometric means or by associating certain questions to answers
provided by the patient that identify the patient to the apparatus,
and cross-referencing this information with the patient information
stored on the networked database. Once the patient is recognized,
the dispensary apparatus prompts the user for a script and the
apparatus processes the user-input script either by the
above-mentioned human validation agent or by processing the machine
readable description (which may be a bar code). This information
can be verified with the server and the database. The apparatus may
also interface with the server to adjudicate insurance claims and
to determine amounts payable by patients. The patient either
accepts or rejects the transaction. If the transaction is accepted,
the apparatus interfaces with the server to transact a payment, for
example, by prompting the patient for credit card information.
Prescription labels and receipts are printed. The apparatus
confirms that the medicament is correct and delivers it to a
dispensing area for retrieval by the user while retaining the
script in a lock box, and verifying that the purchased medicament
product has been retrieved. Further, the apparatus may print and/or
provide to the user educational materials relevant to the
medicaments that have been dispensed. The automated dispensing
apparatus forming one node of a communication network is of
significant value in enabling a patient to obtain prescribed
medicaments without having to attend a pharmacy or medicament
store.
As part of such an automated dispensary, a medicament vault having
a rack assembly is described in U.S. patent application Ser. No.
12/541,307 which is hereby incorporated by reference in its
entirety. As shown in FIG. 1, such a vault 10 includes a row column
rack 11 of bins 12, each of the bins being rectangular in form,
although other bin shapes are contemplated. The rack structure
permits the spacing of bin side walls and the spacing of bin floors
from their tops to be readily altered. By suitable selection of the
spacings, a large variety of sizes can be obtained. Medicament
packages may have a range of shapes and sizes depending on both the
size of the medicament itself and the size of the surrounding
packaging. Because space is at a premium, ideally the size of a
particular bin 12 should closely match the size of the medicament
package housed in that bin. Because the distribution of package
size distribution normally varies from dispensary to dispensary,
the distribution of bin sizes in a bin rack is tailored for the
particular dispensary.
The automated dispensary also includes a package handling
apparatus. As shown in FIG. 1, the apparatus includes a gantry on
which is mounted a pick head. The gantry includes a vertically
reciprocal carriage 21 which is driven by a belt drive 22 along a
vertical guide rail 23. The rail 23 is mounted between two linked,
horizontally reciprocal carriages 24. The carriages 24 are driven
by a belt drive 26 along horizontal rails 28. The carriages 21 and
24 are movable in an access plane extending parallel to a front
side of the bin rack 11. In this way, a pick head 20 can be placed
adjacent any selected one of the storage bins 12 or any other
functional station forming part of the vault. To pick a package
from a bin, a platform forming part of the pick head is moved in a
direction perpendicular to the access plane to a position from
where a selected package can be withdrawn from a chosen bin or can
be placed into a chosen bin.
One form of pick head mechanism for use with the illustrated rack
is described in U.S. patent application Ser. No. 12/503,989 which
is hereby incorporated by reference in its entirety. As shown in
the perspective view of FIG. 2, such a mechanism includes a
telescopic supporting linkage 34 driven by a motor 36 and a belt 38
which are operable to drive a platform 32 supported on the linkage
34 into and out of the rack to pick or load a package at a selected
bin. During a package picking procedure, the platform is driven
into the selected bin where the package to be picked is caused to
seat on the platform. The pick head mechanism is then actuated to
withdraw the platform 32 from the selected bin or station and, at
the same time, to drag the selected package onto the platform from
where it is carried by the pick head 20 to another station within
the dispensary. In a package place cycle, the package is initially
supported on the platform 32. Then, as a result of the platform
being driven into a chosen storage bin, the package is caused to
dislodge and remain in the storage bin as the platform is
withdrawn. The pick head mechanism is used to pick/place a selected
package from/to a selected one of the stations/bins. If the
selected package is part of a stack or row of packages, the pick
head also picks/loads the package from/to a selected position
within the stack or row.
It is important for patient convenience and safety that handling of
medicament packages within the medicament vault be effected
efficiently and securely in the course of various package handling
procedures such as initial loading, subsequent inventory
management, and dispensing. A valuable preparatory step for such
handling is the serialization of all products that are stored at
the dispensary.
As shown in the schematic diagram of FIG. 3, the dispensary has an
inspection module 40, an image processing module 42 and a
serializing module 44. The dispensary modules are connected through
an interface module to remote access modules 46 and other automated
dispensaries forming a data communications network. Each of these
general modules may include a number of sub-modules. The remote
access modules 46 may for example include data input and output
means for a doctor, a pharmacist, an inventory control network, and
databases for drug data, patient drug history and patient medical
history.
Package handling control is provided by a general processing module
48, a memory module 50 storing program instructions and other data
to be used in the package handling control, and a connection bus
52. The processing module 48 may be a single processing device or a
plurality of processing devices. Such a processing device may be a
microcontroller, microprocessor, microcomputer, central processing
unit, digital signal processor, programmable gate array, state
machine, logic circuitry, and/or any device that manipulates
signals (analog and/or digital) based on operational instructions.
The memory module 50 may be a single memory device or a plurality
of memory devices. Such a memory device may be a read-only memory,
random access memory, system memory, flash memory, magnetic tape
memory, programmable memory, erasable memory, and/or any device
that stores digital information.
Elements of the inspection module 40 are housed in an inspection
station to which packages are brought and loaded for inspection in
the course of serialization and at other times during their
handling in the dispensary. As shown in FIG. 4, the inspection
station includes a rectangular housing 54 having walls 56 in which
are mounted optical sensors 58 that are triggered when the pick
head 20 transfers a package into an inspection zone of the
inspection station. Outputs from the optical sensors are used to
generate command signals for maneuvering the pick head so as
accurately to place the package at a desired position on an
inspection platform 60. Initial position and orientation of the
package are selected to minimize subsequent processing
requirements.
Constructed as part of the inspection station as shown in the
circuit schematic diagram of FIG. 3 are an illumination module 62
and an image capture module 64. The illumination module has several
light sources, which illuminate a package positioned at the
inspection zone from multiple directions. Each source has an array
of light emitting diodes (LEDs) 66 with light from each LED being
focused by a respective lens 68 onto a corresponding surface of the
package. The package is illuminated from above, and from top,
bottom and both sides. In addition, for detecting and analyzing
embossed characters, the package may be illuminated by other LED
array sources (not shown) that direct light at a low angle to the
package surfaces.
The image capture module includes cameras 70 mounted at positions
where they capture an image from respective illuminated surfaces of
the package when located at the inspection zone. The illumination
and image capture modules are programmed to cycle through operation
cycles so as to capture an image of each surface of the package.
Packages are ideally placed into the inspection station at a
location and with an orientation where, for a rectangular package
and for reading printed characters from the package surfaces, each
surface extends in a plane generally perpendicular to the direction
of illuminating light and also generally perpendicularly to the
viewing axis of a respective camera. In the FIG. 4 embodiment, the
package (not shown) is maintained in a fixed position on the
platform 60, while an illumination and image capture sequence takes
place to capture images from the surfaces of the package.
In an alternative embodiment of the invention, an inspection
station 54 includes a package manipulation module 71 as shown in
FIG. 3 as part of the inspection module 40 and as shown in
perspective view in FIG. 5. The package manipulation module 71
includes a first mechanism 72 for rotating a medicament package
placed at an inspection zone around a vertical axis. During an
inspection cycle, the medicament packages is supported on a base
that is driven by a stepper motor to step the package through a
series of orientations, one of which is shown in broken line in
FIG. 6, showing a top view of the interior of the inspection
station. Operation of the stepper motor is synchronized with
operation of the light sources of the illumination module and
operation of the cameras of the image capture module. The
manipulation module has a second mechanism 74, part of which is
shown in FIG. 7, for rotating the medicament package about a
horizontal axis. The second mechanism includes a set of clamping
pads 78 at the end of actuating rods 80, the rods being mounted for
reciprocal movement along their longitudinal axes, and for rotation
about their axes. During an inspection cycle, with a package 8
located at the inspection zone, the actuating rods 80 are caused to
move against the package to grip it, are moved vertically to lift
the package from the base, and are then caused to rotate about
their longitudinal axes to spin the medicament package about a
generally horizontal axis to bring top, bottom and two side
surfaces successively before a light source of the illumination
module. The operation of the second mechanism 74 is also
synchronized with operation of the light sources 66 of the
illumination module and operation of the cameras 70 of the image
capture module. Parameters of the mechanisms 72, 74 are chosen to
achieve the desired capture of images of the various surfaces of
medicament packages placed at the inspection zone.
In a further modification of the manipulation module, the
inspection station has a bay defined by three mutually
perpendicular plates having an apex point. The pick head control is
programmed to drive a package inserted into the inspection zone as
far as possible into the bay towards the apex point with the
package resting against the interior faces of the plates. The
plates are transparent and cameras 70 are positioned on a side of
respective plates remote from the bay interior. Each of the cameras
has a field of view and depth of focus so as to span a
predetermined area of the interior face of the corresponding plate.
In this way, when a package is driven into position in the bay it
is automatically at a position to obtain an image of each of its
three `contact" surfaces. Following imaging of the three faces, the
package is gripped by an arrangement similar to that shown in FIGS.
5 and 7, and withdrawn from the bay. The package is turned
180.degree. about one axis, then turned 180.degree. about a
perpendicular axis and finally driven back into the bay to the apex
point whereupon images of the three other sides are captured. It
will be appreciated that such a confined bay lends itself
particularly to rectangular packages but is not as effective for
packages with a round or irregular profile. In the latter, at the
expense of a more complex mechanical arrangement, the plates may be
dispensed with, the manipulation module then simply manipulating
packages against virtual datum points or planes. Generally, by
using a module such as the manipulation module 71, the illumination
and image capture modules can be constructed with fewer elements
because the package itself is moved to bring each of several
surfaces to a position at which they are illuminated and at which a
desired image or images of the illuminated surface is captured.
However, as is evident, a more complex mechanical arrangement is
required.
As shown in FIG. 3, an output from the inspection station
representing the captured image is taken to the image processing
module 42 which is operable to improve captured image quality and
to identify characters. The image processing module includes an
optical character recognition (OCR) module 76 optimized for reading
printed machine-readable characters. The OCR module also includes
an embossed character reader 82 for reading embossed characters
often used for important package data such as lot number and expiry
date. The embossed character reader can be as described in U.S.
patent application Ser. No. 12/642,786 and can include dedicated
illumination sources configured to project light at a low angle to
the package surfaces to increase the ease of detecting and
identifying the embossed characters.
The output from the OCR module 76 is fed to an interpretation
module 84 interpretation which has a reference input from the
serialization module 44 related to permitted and likely formats and
content for characters and character sets that are expected to be
read from the medicament package. These may include, for example,
particular sequences of alphanumeric characters that normally
signify a lot number or an expiry date; or the presence of
separation spacing and characters between character strings of
interest; or a particular format required by government
regulations. The OCR output data is compared with the permitted and
likely formats data to detect matches and so increase the
confidence level of characters preliminarily identified at the OCR
module. On the basis of a comparison between the OCR output and the
expected data inputs at the interpretation module, OCR outputs are
either confirmed as valid or are considered to be suspect.
Feedback control from the image processing module 42 is used for
closed-loop analog tuning of the illumination module 62 and the
image capture module 64. The feedback control may be configured as
cascaded feedback with an output from one or more secondary
feedback loop being used to reconfigure settings and with feedback
from a primary loop being used to obtain a final output.
The output of the interpretation module 84 is taken to a
presentation module 86 which is configured automatically to mark
the image of the corresponding medicament package, as first
captured by the image capture module 64, to highlight any character
whose identity is in question. The output of the presentation
module is transmitted to a manual inspection module 88 where a
human inspector is present with access to monitor means the
transmitted image is displayed for visual inspection by the
inspector. The manual inspection module is located at a node on the
communication network that is remote from the automated dispensary.
For convenience, although the inspection module is at a remote
node, it is shown in FIG. 3 as being part of the image processing
module 42. The inspection module has input means at which the
inspector can key in data to be sent on the network to be combined
with other image data generated at the automated dispensary.
Output data from the image processing module 42 is recorded at a
data acquisition module 90 forming part of the serialization module
44. The recorded data is source data and is visually discernible
from the medicament package as delivered to the automated
dispensary and includes both the images of the package and the
characters that have been identified from those images. The source
data forms one part of characterizing data corresponding to the
medicament package.
In this embodiment of the invention, the characterizing data also
includes derived data related to a physical property of the
package, such as its weight. Such physical data may not be present
in the source data and is not evident from a purely visual
inspection of the medicament package as it is received from the
manufacturer. The physical data is generated by measuring or
otherwise inspecting physical properties of packages by the
measuring module 92 located at the inspection station. As shown in
FIG. 4, the physical property measuring module has a weigh scale
sub-system 94. The weigh scale has four load cells 98 mounted
between a base member 100 and the package-supporting platform 60,
the load cells 98 being located in a symmetrical rectangular array.
The load cells are compression load cells but can alternatively be
tension or shear cells. They are constructed with the required
sensitivity for the relatively light weight of conventional
medicament packages. The cells incorporate strain gauge transducers
but can alternatively incorporate other types of transducer.
Components of the weight of the package are detected at each of the
load cells and converted into corresponding output signals. Based
on prior calibration, the weight of the package is computed. In
addition, by comparing the variation in weight component measured
by the load cells, moments of the package--i.e. the package weight
distribution over the package length and breadth--are determined.
While a rectangular array of load cells is a simple and convenient
arrangement, a single load cell or an alternative array of load
cells can alternatively be used.
It will be appreciated that other physical properties of the
package such as its shape and size may also be measured by
appropriate commercially available measuring units. Outputs from
the physical property measuring module 92 are used to generate
physical data corresponding to the measured physical properties,
with the physical data forming a second data input to the data
acquisition module 90. The combination of the source data and the
physical data constitute the package characterizing data at the
time that the package is serialized.
From the data acquisition module, an output is taken to an encoding
module 104 for generating a code corresponding to the
characterizing data. The code is used to generate a physical bar
code which is applied to the surface of the corresponding package
at a package labeling module 106.
The bar codes consolidate and compress the characterizing data for
the serialized packages and have a consistent format, regardless of
any significant distinction between the nature and properties of
different packages.
The serializing module includes an indexing module 108 at which a
first index is maintained of assigned bar codes against the
corresponding characterizing data associated with the bar codes and
a second index is maintained of the packages, as identified by
their serializing bar codes, against the particular vault stations
within which the packages are located at any time.
An autoserialization method using the above described equipment
will now be described. Ideally, identifying data required for
effective handling of medicament packages would be displayed on the
packages and would have a standardized position, content and
format. For example, all information would be printed black on
white with all alphanumeric characteristics being of a single font
type, stroke width, size and spacing. In fact, labeling of
medicament packages from diverse commercial suppliers is not
standardized to any great extent. Consequently, all incoming
packages must be serialized as part of a standardized serialization
procedure so that the incoming packages can subsequently be
effectively handled within the dispensary.
In the present embodiment of the invention, packages are serialized
in an autoserialization process in the course of a dispensary
loading procedure, with the autoserialization process reusing a
significant part of the result of labeling work done earlier in the
supply chain. However, it will be realized that the
autoserialization and loading processes for a particular medicament
package can be performed at separate times.
Certain of the bins 12 in the vault are designated as loading bins,
meaning that when the vault is first being stocked, or subsequently
restocked, new stock assigned to the dispensary is first loaded
into the loading bins without any particular regard to the nature
or initial location of each package of the new stock. Subsequently,
the packages are loaded into other bins of the vault designated as
storage bins. The loading procedure can be effected at a quiet
time, either when dispensing demand is predicted to be low or when,
by automated monitoring, it is determined that no dispensing or
other inventory management operation is in progress. The particular
bins designated as loading bins can be changed if desired to have
the loading area occupy either a smaller or larger footprint so as
to accommodate a smaller or larger amount of new stock.
When transferring a package of new stock from one of the loading
bins to a designated storage bin, various of the FIG. 3 serializing
modules are actuated to serialize the packages to be loaded. A
package to be serialized is selected and the pick head drive is
actuated to move the pick head to a loading bin and to pick up the
selected package located in one of the loading bins. The selected
package is then brought by the pick head to the inspection station
and inserted by the pick head to a reference position. The pick
head is controlled by a servo-mechanism linked to the optical
sensor arrangement to ensure that the package is accurately
positioned on the inspection platform 60.
An imaging sequence is then initiated at the illumination module.
The LED light sources 66 are operated in turn to illuminate
successive faces of the package. Certain of the light sources are
positioned and configured to emit light which is generally
perpendicular to the surface to be imaged with a view to obtaining
an image showing conventionally printed characters. Other light
sources are configured to direct low angle light onto the surface
to be imaged with a view to obtaining an image showing embossed
characters. Certain of the light sources used may be white light
containing a broad spectrum of wavelengths. These can be
supplemented by single color light sources which can offer clearer
images of specific printed background/foreground combinations. The
operation of the cameras 70 in the image capture module 64 is
synchronized with the operation of light sources of the
illumination module with the illumination and image capture modules
programmed to cycle through an operation cycle so as successively
to capture images from respective illuminated surfaces of the
package when located at the inspection zone.
An output from the inspection station representing the captured
image is taken to the image processing module 42 where the image
quality is improved and where characters in the image are
identified. At the OCR module 76, printed machine-readable
characters are read by the OCR reader unless the image is unclear.
Another input from the inspection module is taken to the embossed
character reader 82 which reads embossed package data such as lot
number and expiry date.
The output from the OCR module 76 is fed to the interpretation
module 84 where it is compared to the reference inputs based on
permitted and likely formats and content of characters. By
detecting matches and the level of confidence in character
identifications that have been preliminarily made at the OCR module
is increased. On the basis of a comparison between the OCR output
and the expected data inputs at the interpretation module, OCR
outputs are either confirmed as valid or are considered to be
suspect.
The output of the interpretation module 84 is taken to the
presentation module 86 where the corresponding medicament package
image, as first captured by the image capture module 64, is
automatically marked to highlight any character whose identity is
in question. The marked image is then displayed at the manual
inspection module 88 where the human inspector visually inspects
each of the questionable characters; i.e. those where a threshold
level of confidence in the machine reading has not been reached.
The inspector after having identified the questionable characters
from displayed source data, keys in the interpretation for
subsequent transmission back to the automated dispensary to be
combined with the image data that has previously been machine read
at the dispensary. The machine reading of characters from a package
at the dispensary and the manual inspection of corresponding images
at the manual inspection station can take place effectively as a
contemporaneous operation. Alternatively, manual inspection tasks
can be queued at a database that is accessed at another time such
that identification of characters applied to a package is a phased
activity.
As previously indicated the image processing module 42 includes one
or more feedback loops. Feedback for tuning control of the
illumination and image capture conditions is implemented by
obtaining a rapid succession of images, scoring the quality of the
images in terms of accurately detecting the characters in the
images, and tuning the imaging conditions optimally to maximize the
scores. The score from the OCR module 76 is used in a primary
feedback loop to the illumination and image capture modules 62, 64
respectively to control, for example, the intensity and direction
of the light sources, and to control various camera settings. The
score is used as an error factor in a succession of PID
(Proportional-Integral-Derivative) calculations to improve the
score, with an optimal score being used as the basis for selecting
final input data to the OCR module. The OCR feedback is used in
real time to improve the imaging score. In addition, feedback is
also used to set initial illumination and imaging conditions for a
package known to be of the same type as that of a previously
analyzed package. The primary feedback loop is combined with one or
more secondary feedback loops from one or more internal sub-systems
of the OCR module so as to increase the speed at which the OCR
module operates. One secondary feedback loop determines which
cameras of the image capture module are to be operational. For
example, if the package is a bottle which invariably has no
information of interest on the top or the bottom, then illumination
sources and cameras occupying positions adjacent the bottle top and
bottom are not operated. By means of another secondary feedback
loop, the image capture module is initially operated to detect any
UPC (universal product code) bar code on the package as obtained
from the supplier. The UPC bar code is read and corresponding
information is accessed from a product database on the network.
From a review of this information, the initial orientation of the
package and the expected position of other data elements on the
packages are predicted. That information is then used as initial
feedback to modify the settings of the illumination and image
capture modules with a view to subsequently obtaining rapid and
clear capture of further relevant image data. Illumination
conditions, such as light intensity and beam direction, and camera
settings, such as brightness, contrast, exposure, gain, focus,
color saturation, zoom, pan and image sharpness, are adjusted in
response to the feedback signals to increase the clarity of the
final images and, therefore, to increase the confidence that a
character is properly identified.
The output from the image processing module 42 is taken to the
serialization module 44 where characterizing data for the package
is generated at the data acquisition module 90 and the
characterizing data is encoded at the encoding module 104. The
serialization module also includes the labeling module 106 for
labeling the package with a bar code representing the
characterizing data, and the indexing module 108 for updating both
the bar code/package index and the package/station index.
As previously described, one part of the package characterizing
data is source data which includes the nature of the medicament,
the manufacturer, the lot number, the expiry date and prescribed
handling instructions. Typically, much of this is derived from a
label bearing a representation of the source data applied to the
medicament package at a prior juncture in the supply chain; for
example, by the manufacturer shortly before the medicament package
exits the manufacturing facility.
As previously described, another part of the characterizing data is
physical data related to the physical properties of the package
such as its weight, shape, size and moment. Such physical data is
normally not evident from a visual inspection of packages as
received for dispensary loading. The physical data is therefore
generated by measuring designated physical properties of the
package (or otherwise automatically physically inspecting the
medicament package) at the physical property measuring module after
the packages are loaded into the loading bins but before they are
assigned to particular storage bins. The source and physical data
are combined as the characterizing data for that package at the
data acquisition module.
The bar code label is placed, where possible, at a consistent
location on all packages so as to render subsequent detection and
reading of bar codes quicker than if the bar codes were placed at
random locations. It will be appreciated that other forms of label,
such as a radio frequency identification label, can be used to
encode the characterizing data and can be applied to packages in a
conventional manner depending on the nature of the label. In
subsequent handling of the labeled package, the bar code is read
and referenced against the bar code/package index.
Once the bar code label is applied to a package at the inspection
station, the pick head 20 is actuated to transfer the package from
the inspection station to a selected one of the storage bins 12 and
to a selected position in a row or stack of packages in that
storage bin.
To select a storage bin within which the package is to be placed, a
selection is made from the package characterizing data of all
factors that determine a permissible bin selection. Because the
vault 10 has a range of bin sizes, one such factor is package size.
Clearly, it is not possible to place the package in a bin which is
too small. Also, it is an inefficient use of space to place the
package in a bin that is much larger than the package. The
characterizing data is also analyzed for other factors that
determine the nature of an acceptable storage bin such as the bin
shape or depth. Some bins may be maintained in a refrigerated zone
to accommodate packaged medicaments whose characterizing data shows
that they are required to be stored at cold temperatures.
Once a suitable bin is identified, the bin index stored at indexing
module 108 is checked to determine whether the bin is already fully
occupied. If the bin is full, then the processing continues to
review the suitability and state of fullness of other suitable
storage bins. When a match of package and storage bin is obtained,
a command sequence is initiated to have the pick head 20 retrieve
the package from the inspection station and transfer it into the
chosen storage bin. As part of the sequence, the package/station
index is updated.
While, generally, the physical actions described in operation of
the automated dispensary take place at the dispensary, because the
dispensary is one node on a communications network, all steps in
the various procedures described which relate to data access,
storage and processing can readily take place at remote nodes of
the network.
It will be seen that it is convenient, in the interests of
efficient use of space and minimizing necessary physical movements
of mechanical systems in the dispensary, to perform the various
operations such as illumination, image capture, physical property
measuring, package labeling, etc., at a single station configured
to enable the performance of each of the operations. However, it
will be understood that, the some of the operations can be
performed at one station while other operations are performed at
another station. To this end, the multiple stations can be
configured differently or can be substantially identical to permit
parallel processing of the operations on different packages. There
is no intention that the implementation of operations involved in
each of the procedures described should all be confined to one
station of the dispensary if it should be found to be convenient to
distribute the steps between different stations.
Although the storage stations of the illustrated embodiments are
shown as a XY array of bins, the storage stations can be otherwise
implemented. For example, in another embodiment of the invention,
the bins have floors/ceilings but do not have side walls. Instead,
packages are accurately placed at station locations along floor
panels extending over at least part of the width of the rack, each
package being separated from a next adjacent package not by a wall,
but by an indexed space.
Other variations and modifications will be apparent to those
skilled in the art. The embodiments of the invention described and
illustrated are not intended to be limiting. The principles of the
invention contemplate many alternatives having advantages and
properties evident in the exemplary embodiments.
* * * * *